Far Infrared Ray Ceramic Plate Heating Module

ABSTRACT

A far infrared ray ceramic flat plate heating module is provided. The far infrared ray ceramic flat plate heating module includes a ceramic heat-generating flat plate, an integrated terminal block for electrical distribution, a metal plate and a metal frame. The ceramic heat-generating flat plate includes a ceramic flat plate, a heat-generating film coated on a surface of the ceramic flat plate, silver paste electrodes configured on and coupled to two opposite sides of the heat-generating film, a first insulating layer coated on the heat-generating film and the silver paste electrodes, a temperature sensor configured by forming a temperature sensing paint layer on the first insulating layer, and a second insulating layer formed on the temperature sensor. The integrated terminal block is secured on the metal plate. The metal frame is disposed surrounding the periphery of the metal plate and the ceramic heat-generating flat plate.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a far infrared ray ceramicflat plate heating module, and more particularly, to a far infrared rayceramic flat plate heating module configured by forming a far infraredray heating film, a silver paste electrode, a first insulating layer, atemperature sensing paint layer, output contact point terminals, asecond insulating layer on a ceramic flat plate. Such a far infrared rayceramic flat plate heating module can be widely applied in producingmany products, such as heat radiators, BBQ grills, and clean furnaces.

2. The Prior Arts

Heat radiators are very popular in the temperate zone and the cold zone,and have become standardized equipment in recently built buildings.Conventional heat radiators generally include fin-type heat radiators,quartz tube heaters, oil burning heaters, and positive temperatureco-efficient (PTC) ceramic forced-draft heaters. Typically, aconventional fin-type heat radiator is operated by forming an innerthermal circulation with hot water or hot kerosene for continuouslyheating the fins. The fins then heat up the air therearound thusconfiguring a convection of the heated air. The fin-type heat radiatorsare usually known as featured with a low energy efficiency and requiringa long time for achieving the desired temperature. As to the quartz tubeheater, it includes a nickel-chrome wire received in a quartz tube forgenerating hot red light radiation. Such a radiation is a visible lightradiation and is also featured with a low energy efficiency. Evenfurther, such a hot red light often makes people feel uncomfortable, andwhen being radiated for a long time, the skin of the user may even betanned or burned. On another hand, when the quartz tube is heated to ahigh temperature, it may explode and injuries the user. Regarding theoil burning heaters, they combust oil to obtain heat. However, when theoil is combusted, it consumes oxygen, and incomplete combustion of oilusually generates carbon monoxide which may cause intoxication of theuser. Further, a PTC ceramic forced-draft heater utilizes forced hot aircirculation for heating. However, when water is splashed on the PTCceramic plate, it may explode. Further, the PTC ceramic plate containslead oxide ingredient, and therefore the production of the PTC ceramicforced-draft heaters may cause lead pollution.

BBQ grill is an ordinary cookware. A conventional BBQ grill is typicallyfabricated by burying a nickel-chrome heating tube in an aluminumcasting flat plate. The surface designed for contacting the food iscoated with a Teflon layer for avoiding sticking. However, the foodcooked with such a conventional BBQ grill often lose lots of watercontent, thus having an unsatisfactory mouth feel.

Furthermore, a typical clean furnace employ a microcrystalline glass(also known as glass-ceramic) serving as a heating panel, and ahigh-power halogen tube is used as the heat source. Such a clean furnaceis attributed to an indirect heating approach and relies upon visiblelight heat-radiation.

In view of the above-mentioned disadvantages and difficulties of theforegoing conventional technologies, and responsive to the demand forhealthy, environment-friendly, and energy saving lifestyle, anew-generation far infrared ray nano heating film and thick carbonheating film have been developed. However, in practical use, such filmsare required to be formed on a carrier which is insulated and highheat-resistant. Ceramic substrates are believed to be a good choice forserving as the carriers. However, ceramic material is usually brittleand is often broken under external impact. As such, a far infrared rayceramic flat plate heating module which is fast-heated, safe, healthy,and environment-friendly, is very much desired for being employed in theforegoing products as a solution of the above-mentioned disadvantagesand difficulties thereof.

SUMMARY OF THE INVENTION

A primary objective of the present invention is to provide a farinfrared ray ceramic flat plate heating module. The far infrared rayceramic flat plate heating module is not likely to be broken by externalimpact so as to cause an electric shock hazard.

The far infrared ray ceramic flat plate heating module includes aceramic heat-generating flat plate, an integrated terminal block, ametal plate, and a metal frame.

The ceramic heat-generating flat plate includes a ceramic flat plate, aheat-generating film coated on a surface of the ceramic flat plate,silver paste electrodes configured on and coupled to two opposite sidesof the heat-generating film, a first insulating layer coated on theheat-generating film and the silver paste electrodes, a temperaturesensor configured by forming a temperature sensing paint layer on thefirst insulating layer. Each of the silver paste electrodes has acontact point exposed out from the first insulating layer, and thecontact points of the silver paste electrodes serve as power supplyingcontact points of the heat-generating film. The temperature sensingpaint layer is preferably formed by a temperature sensing paint and isconfigured as a polygonal open loop. The polygonal open loop breaks at acertain position with two terminals. The two terminals of the polygonalopen loop are coated with silver paste for forming two contact points ofthe temperature sensor. When the ceramic heat-generating flat plategenerates heat, a resistance variation between the two contact points ofthe temperature sensor is detected by a circuit. Therefore, an inputpower of the ceramic heat-generating flat plate is adjusted according tothe detected resistance variation for controlling a temperature of theceramic heat-generating flat plate.

The integrated terminal block includes input/output contact pointterminals. The input/output contact point terminals are electricallycoupled to the power supplying contact points of the heat-generatingfilm and the contact points of the temperature sensor. The integratedterminal block is secured on the metal plate.

The metal frame is disposed surrounding a periphery of the ceramicheat-generating flat plate, and the ceramic heat-generating flat plateis secured on the metal plate.

The present invention has the following advantages:

1. The far infrared ray ceramic flat plate heating module of the presentinvention employs a metal frame and a metal plate for securing andprotecting the ceramic heat-generating flat plate from being broken byexternal impact and electric shock hazard caused thereby. The farinfrared ray ceramic flat plate heating module of the present inventionproduces the heat in the form of far infrared ray which is beneficial topeople's health. When employed for warming, the far infrared ray ceramicflat plate heating module of the present invention is adapted forproviding a comfortable and warm condition for the user. When employedin a BBQ grill, the far infrared ray ceramic flat plate heating moduleof the present invention is adapted for maintaining the delicious tasteof the food. When employed in a clean furnace, the far infrared rayceramic flat plate heating module of the present invention is adaptedfor achieving a higher efficiency; and

2. The far infrared ray ceramic flat plate heating module of the presentinvention has a simple and compatible structure, which can beconveniently used in designing far infrared ray heating products.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be apparent to those skilled in the art byreading the following detailed description of preferred embodimentsthereof, with reference to the attached drawings, in which:

FIG. 1 is a perspective exploded view of a far infrared ray ceramic flatplate heating module according to an embodiment of the presentinvention; and

FIG. 2 is a perspective exploded view of a ceramic heat-generating flatplate of the far infrared ray ceramic flat plate heating moduleaccording to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The accompanying drawings are included to provide a furtherunderstanding of the invention, and are incorporated in and constitute apart of this specification. The drawing illustrates embodiments of theinvention and, together with the description, serves to explain theprinciples of the invention.

Referring to FIGS. 1 and 2, a far infrared ray ceramic flat plateheating module according to an embodiment of the present inventionincludes a ceramic heat-generating flat plate 1, an integrated terminalblock 7, a frame fixing element, a metal plate 4, and a metal frame 2.

The ceramic heat-generating flat plate 1 includes a ceramic flat plate11, a heat-generating film 12 coated on a surface of the ceramic flatplate 11, silver paste electrodes 13 configured on and coupled to twoopposite sides of the heat-generating film 12, a first insulating layer14 coated on the heat-generating film 12 and the silver paste electrodes13, a temperature sensor configured by forming a temperature sensingpaint layer 16, and a second insulating layer 18 on the first insulatinglayer 14. The ceramic flat plate 11 for example is an aluminum oxideceramic plate or a microcrystalline glass plate. The silver pasteelectrodes 13 are formed in strip type, and configured by coating asilver paste at the two opposite sides of the heat-generating film 12.When a power supply is provided over the two silver paste electrodes,the heat-generating film 12 obtains power therefrom so as to heat up theceramic flat plate 11. The heat-generating film 12 for example can be aheat-generating thick film such as a thick carbon heating film, orheat-generating thin film such as a nano heating film. Each of thesilver paste electrodes 13 has a contact point exposed out from thefirst insulating layer 14, and the contact points of the silver pasteelectrodes 13 serve as power supplying contact points 15 of theheat-generating film 12. The temperature sensing paint layer 16 ispreferably formed by a temperature sensing paint and is configured as apolygonal open loop having a breaking point. The polygonal open looppresents two terminals at the breaking point. The two terminals of thepolygonal open loop are coated with silver paste for forming two contactpoints 17 of the temperature sensor. The temperature sensing paint forexample can be a negative temperature coefficient (NTC) thermistor paintor a positive temperature coefficient (PTC) thermistor paint. Thepolygonal open loop for example is but not restricted to be arectangular loop. The second insulating layer 18 is provided forprotecting the temperature sensing paint layer 16 and improving theanti-creeping performance of the ceramic heat-generating flat plate 1.The second insulating layer 18 for example is made of aluminum oxide.The two contact points 17 of the temperature sensor is exposed from thesecond insulating layer 18. When the ceramic heat-generating flat plate1 generates the heat, a resistance variation between the two contactpoints 17 of the temperature sensor is detected by a circuit. Therefore,an input power of the ceramic heat-generating flat plate 1 is adjustedaccording to the detected resistance variation for controlling atemperature of the ceramic heat-generating flat plate 1. In case theceramic flat plate 11 is broken by an external impact, the polygonalopen loop is cut off, and the resistance of the temperature sensingpaint layer 16 connected between the two contact points 17 of thetemperature sensor become infinite. In such a way, the power supply isimmediately cut off, so as to avoid the electric shock hazard.

The metal frame 2 is disposed surrounding a periphery of the ceramicheat-generating flat plate 1, and the ceramic heat-generating flat plate1 is secured at one side of the metal plate 4 for enforcing the strengthof the ceramic heat-generating flat plate 1 against external impact.Furthermore, the metal plate 4 is adapted for reflecting the farinfrared ray emitted from the ceramic heat-generating flat plate 1 so asto lower the temperature at the bottom side of the ceramic flat plate11. According to an aspect of the embodiment, the far infrared rayceramic flat plate heating module further includes power supplying inputterminals 5 and an output terminal 6 of the temperature sensor. Thepower supplying input terminals 5 and the output terminal 6 of thetemperature sensor are secured on the metal plate. As shown in FIGS. 1and 2, the power supplying input terminals 5 are coupled in directcontact with the power supplying contact points 15, and the outputterminal 6 is coupled in direct contact with the two contact points 17of the temperature sensor.

The frame fixing element is composed of a heat-resistant rubber ringframe 3. The heat-resistant rubber ring frame 3 for example is made of asilica gel, and is provided between the metal frame 2 and a periphery ofthe ceramic heat-generating flat plate 1 for providing a shock-absorbingbuffer therebetween.

The integrated terminal block 7 is secured on the metal plate 4. Theintegrated terminal block 7 includes input/output contact pointterminals. The power supplying contact points 15 of the ceramicheat-generating flat plate 1, and the two contact points 17 of thetemperature sensor are electrically coupled to the input/output contactpoint terminals via the power supplying input terminals 5 and the outputterminal 6. The integrated terminal block 7 further includes atemperature switch 71 and a temperature fuse 72 at a side adjacent tothe ceramic flat plate 11. When the operation temperature is abnormal,the temperature switch 71 is cut off to stop the power supplying to theceramic heat-generating flat plate 1. When the abnormal temperaturecondition sustains for a certain time, the temperature fuse 72 is blownto stop the power supplying to the ceramic heat-generating flat plate 1.In such a way, in case the ceramic heat-generating flat plate 1 works inan abnormal condition, the far infrared ray ceramic flat plate heatingmodule can be protected from being damaged or causing a fire or electricshock hazard.

In summary, the present invention provides a far infrared ray ceramicflat plate heating module, adapted for being applied in many productssuch as heat radiators, BBQ grills, and clean furnaces. The far infraredray ceramic flat plate heating module is modularized so as to allowdesigners to design applicable, power saving, and safe far infrared rayheating products with the far infrared ray ceramic flat plate heatingmodule of the present invention.

Although the present invention has been described with reference to thepreferred embodiments thereof, it is apparent to those skilled in theart that a variety of modifications and changes may be made withoutdeparting from the scope of the present invention which is intended tobe defined by the appended claims.

1. A far infrared ray ceramic flat plate heating module, comprising: aceramic heat-generating flat plate, comprising: a ceramic flat plate; aheat-generating film coated on a surface of the ceramic flat plate;silver paste electrodes configured on and coupled to two opposite sidesof the heat-generating film; a first insulating layer coated on theheat-generating film and the silver paste electrodes, wherein each ofthe silver paste electrodes has a contact point exposed out from thefirst insulating layer, and the contact points of the silver pasteelectrodes serve as power supplying contact points of theheat-generating film; and a temperature sensor configured by forming atemperature sensing paint layer on the first insulating layer, whereinthe temperature sensing paint layer is formed by a temperature sensingpaint and is configured as a polygonal open loop, wherein the polygonalopen loop breaks at a certain position with two terminals, and the twoterminals of the polygonal open loop are coated with silver paste forforming two contact points of the temperature sensor; a metal plate,wherein the ceramic heat-generating flat plate is secured on the metalplate; an integrated terminal block, being secured on the metal plateand comprising input/output contact point terminals configured thereon,wherein the input/output contact point terminals are electricallycoupled to the power supplying contact points of the heat-generatingfilm and the contact points of the temperature sensor; and a metal framedisposed surrounding a periphery of the ceramic heat-generating flatplate.
 2. The far infrared ray ceramic flat plate heating module asclaimed in claim 1, wherein the polygonal open loop is a rectangularopen loop
 3. The far infrared ray ceramic flat plate heating module asclaimed in claim 1, wherein the ceramic heat-generating flat platefurther comprises a second insulating layer coated on the temperaturesensing paint layer, and the contact points of the temperature sensorare exposed out from the second insulating layer.
 4. The far infraredray ceramic flat plate heating module as claimed in claim 1, furthercomprising a heat-resistant rubber ring frame provided between the metalframe and a periphery of the ceramic heat-generating flat plate forproviding a shock-absorbing buffer therebetween.
 5. The far infrared rayceramic flat plate heating module as claimed in claim 1, wherein theceramic flat plate is an aluminum oxide ceramic plate or amicrocrystalline glass plate.
 6. The far infrared ray ceramic flat plateheating module as claimed in claim 1, wherein the heat-generating filmis a carbon heating film, or a nano heating film.
 7. The far infraredray ceramic flat plate heating module as claimed in claim 1, wherein thefirst insulating layer is made of aluminum oxide.
 8. The far infraredray ceramic flat plate heating module as claimed in claim 3, wherein thesecond insulating layer is made of aluminum oxide.
 9. The far infraredray ceramic flat plate heating module as claimed in claim 1, wherein thefar infrared ray ceramic flat plate heating module further comprisespower supplying input terminals of the ceramic heat-generating flatplate and an output terminal of the temperature sensor, wherein thepower supplying contact points of the ceramic heat-generating flatplate, and the two contact points of the temperature sensor areelectrically coupled to the input/output contact point terminals via thepower supplying input terminals and the output terminal.
 10. The farinfrared ray ceramic flat plate heating module as claimed in claim 1,wherein the temperature sensing paint is a negative temperaturecoefficient (NTC) thermistor paint or a positive temperature coefficient(PTC) thermistor paint.
 11. The far infrared ray ceramic flat plateheating module as claimed in claim 4, wherein the heat-resistant rubberring frame is made of a silica gel material.